OVERDRIVE DIRECT CLUTCH > REASSEMBLY

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1. INSTALL NO. 3 OVERDRIVE PLANETARY GEAR THRUST WASHER


AT08148E01

  1. Install the thrust washer to the overdrive planetary gear with the groove side facing upward.



2. INSTALL OVERDRIVE ONE-WAY CLUTCH


AT04451E03

  1. Install the 2 retainers to the one-way clutch.

  1. Install the one-way clutch into the outer race with the flange side of the one-way clutch facing upward.



    AT01638E01

  1. Install the overdrive one-way clutch and outer race to the overdrive planetary gear.



3. INSTALL OVERDRIVE RETAINING PLATE


AT08146E01

  1. Install the retaining plate.



    AT08135E01

  1. Using a screwdriver, install the snap ring.



4. INSTALL OVERDRIVE PLANETARY RING GEAR FLANGE


AT08134E01

  1. Install the ring gear flange.



    AT08133E01

  1. Using a screwdriver, install the snap ring.



5. INSTALL OVERDRIVE DIRECT CLUTCH PISTON


AT08144E01

  1. Coat new O-rings with ATF, and install them on the overdrive direct clutch piston.

  1. Being careful not to damage the O-rings, and press in the direct clutch piston into the clutch drum with both hands.



6. INSTALL OVERDRIVE DIRECT CLUTCH RETURN SPRING


AT08145E01


    Z004660E01

  1. Place SST on the spring retainer, and compress the return spring with a press.

    SST
    09350-30020   (09350-07040)

  1. Using a screwdriver, install the snap ring.

    NOTICE:
    1. Do not deform the spring sheet. Stop compressing when the spring sheet is lowered to 1 to 2 mm (0.039 to 0.078 in.) from the snap ring groove.
    2. Be sure the end gap of the snap ring is not aligned with the spring retainer claw.



7. INSTALL OVERDRIVE DIRECT CLUTCH DISC


AT01639E01

  1. Install the 2 plates and discs.

    Install in order:
    P - D - P - D

    HINT:
    P = Plate
    D = Disc



    AT08155E01

  1. Install the flange with the flat end facing downward.

  1. Using a screwdriver, install the snap ring.



8. INSPECT PISTON STROKE OF OVERDRIVE DIRECT CLUTCH


AT08140E01

  1. Place the oil pump onto the torque converter clutch, and then place the overdrive direct clutch drum assembly onto the oil pump.



    AT04448E01

  1. Using SST and a dial indicator, measure the overdrive direct clutch piston stroke while applying and releasing compressed air (392 kPa (4.0 kgf/cm2, 57 psi)).

    SST
    09350-30020   (09350-06120)

    Piston stroke:
    1.85 to 2.15 mm (0.0728 to 0.0846 in.)

    If the piston stroke is not as specified, parts may have been assembled incorrectly. Check and reassemble again.

    HINT:
    1. If the piston stroke is still not as specified, select another flange.
    2. There are 8 different flange thicknesses.

    Flange thickness:
    No.
    		Thickness
    		No.
    		Thickness
    08
    		3.8 mm (0.150 in.)
    		04
    		3.4 mm (0.134 in.)
    07
    		3.7 mm (0.146 in.)
    		03
    		3.3 mm (0.130 in.)
    06
    		3.6 mm (0.142 in.)
    		02
    		3.2 mm (0.126 in.)
    05
    		3.5 mm (0.138 in.)
    		01
    		3.1 mm (0.122 in.)



9. INSTALL OVERDRIVE DIRECT CLUTCH DRUM


AT08130E01

  1. Align the flukes of the discs in the direct clutch assembly.

  1. Install the direct clutch drum assembly onto the overdrive planetary gear.



10. INSPECT OVERDRIVE ONE-WAY CLUTCH


AT08138E01

  1. Hold the overdrive direct clutch drum, and turn the input shaft.
    Check that the input shaft can be turned freely clockwise and locks when turned counterclockwise.